Alfalaval Unique Single Seat Valve User manual

Instruction Manual
Unique Single Seat Valve - ATEX Standard
TD 474-001
ESE00674-EN3 2011-05
Original manual

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 8
3.1. Unpacking/delivery ............................................................................... 8
3.2. General installation ................................................................................ 10
3.3. Welding ............................................................................................ 11
3.4. Recycling information ............................................................................. 12
4. Operation ............................................................................................... 13
4.1. Operation .......................................................................................... 13
4.2. Troubleshooting ................................................................................... 15
4.3. Recommended cleaning ......................................................................... 16
5. Maintenance ........................................................................................... 18
5.1. General maintenance ............................................................................. 18
5.2. Dismantling of valve .............................................................................. 20
5.3. Plug seal replacement ............................................................................ 21
5.4. Assembly of valve ................................................................................. 21
5.5. Actuator bushing replacement .................................................................. 22
5.6. Dismantling of optional maintainable actuator ................................................. 22
5.7. Use ................................................................................................. 22
5.8. Additional equipment ............................................................................. 23
6. Technical data ......................................................................................... 24
6.1. Technical data ..................................................................................... 24
7. Parts list and Service Kits ........................................................................... 26
7.1. Drawing ............................................................................................ 26
7.2. Unique Single Seat Valve ......................................................................... 27
7.3. Drawing ............................................................................................ 32
7.4. Unique Single Seat Valve - Reverse Acting .................................................... 33
7.5. Maintainable actuator ............................................................................ 37
3

1 EC Declaration of Conformity
The designating company
Alfa Laval
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Unique Single Seat Valve Standard and Reverse Acting
Denomination Type Year
is in conformity with the following directives:
- Machinery Directive 2006/42/EC
- Pressure Equipment Directive 97/23/EC category 1 and subjected to assessment procedure Module A.
Manager, Product Centres, Compact
Heat Exchangers & Fluid Handling
Bjarne Søndergaard
Title Name
Alfa Laval Kolding
Company Signature
Designation
4

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
2.1 Important information
Always read the manual before using the valve!
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the valve.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Caustic agents:
5

2Safety
All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury and/or damage to the valve are avoided.
2.3 Safety precautions
Installation
Always read the technical data thoroughly.
Always release compressed air after use.
Never touch the moving parts if the actuator is supplied with compressed air.
Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
Never dismantle the valve with valve and pipelines under pressure.
Never dismantle the valve when it is hot.
Operation
Never dismantle the valve with valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
Always read the technical data thoroughly.
Always release compressed air after use.
Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
Never touch the moving parts if the actuator is supplied with compressed air.
Always rinse well with clean water after the cleaning.
Beware of min./max. temperatures.
Always handle lye and acid with great care.
Maintenance
ATEX Version only by use of genuine Alfa Laval parts.
Never replace ATEX actuator with other type of Alfa Laval actuators.
Spareparts: see also Parts Lists and Service Kits. Chapter 7.
Always read the technical data thoroughly.
Always release compressed air after use.
Never service the valve when it is hot.
Never service the valve with valve and pipelines under pressure.
Never stick your fingers through the valve ports if the actuator is supplied with compressed air.
Never touch the moving parts if the actuator is supplied with compressed air.
6

2 Safety
All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury and/or damage to the valve are avoided.
Transportation:
Always secure that compressed air is released
Always secure that all connections is disconnected before attemt to remove the valve from the installation
Always drain liquid out of valves before transportation
Always used predesigned lifting points if defined
Always secure sufficient fixing of the valve during transportation - if special designed packaging material is available it must
be used
7

3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The items refer to parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve, shut off valve (RA) or change-over
valve(RA)(seesteps2a,2b,2cand2d).
2. Delivery note.
Step 2
2a
Shut-off valve:
1. Complete actuator.
2. Bonnet (20).
3. Clamp (19).
4. Valve plug (23).
5. Valve body (22).
6. Ground wire (64).
TD 461-943
64
2b
Change-over valve:
1. Complete actuator.
2. Bonnet (20).
3. 2 x clamp (19).
4. Valve plug (27).
5. Lower valve body (22).
6. Valve seat (28).
7. Upper valve body (26).
8. Ground wire (64).
TD 461-944_1
64
UP
2c
Shut-off valve - Reverse Acting:
1. Complete actuator.
2. Bonnet (20).
3. 3 x clamp (19).
4. Valve plug (23).
5. 2 x upper valve body (26).
6. Valve seat (28).
7. Lower bonnet (33).
8. Ground wire (64).
TD 461-945_1
64
UP
8

3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The items refer to parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
2d
Change-over valve - Reverse Acting:
1. Complete actuator.
2. Bonnet (20).
3. 4 x clamp (19).
4. Upper valve plug (34).
5. Lower valve plug (35).
6. 3 x upper valve body (26).
7. 2 x valve seat (28).
8. Lower bonnet (33).
9. Ground wire (64).
TD 461-946_1
64
UP
Step 3
Remove possible packing materials from the valve/valve parts.
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends as standard but can also be supplied with fittings.
3.2 General installation
Step 1
Always read the technical data thoroughly.
See chapter
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
Step 2
Never touch the moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
TD 461-006_01
Step 3
It is recommended to install the valve so that the flow is against
the closing direction to avoid water hammer.
Shock in the actuator must never occur.
Avoid water
hammering!
Inlet
TD 461-947
Inlet
Step 4
Avoid stressing the valve.
Pay special attention to:
-Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
TD 461-948
10

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.3 Welding
Step 1
Always install valves with more than one valve body so that the
seals between the valve bodies can be replaced. Do not weld
more than one valve body into the system.
Valve size A (mm) B (mm)
DN25/25 mm *630
DN40/38 mm *700
DN50/51 mm *750
DN65/63.5 mm *740
DN80/76 mm *800
DN100/101.6 mm *790
* Depending on body combination and piping solution.
B(incl.topunit)
A*
Step 2
Assemble the valve in accordance with the steps on page 21.
Pay special attention to the warnings!
TD 461-949
TD 461-950
Step 3
Pre-use check:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to ensure that it
operates smoothly.
Pay special attention to the warnings!
Air
Air
Open/close!
TD 461-951
Step 4
Make sure the groun wire has electrical connection to plug and
actuator.
All conducting parts or equipment must be arranged to avoid that
a dangerous potential difference can exist between them. If there is
a possibility of isolated metal parts becoming charged and acting
as an ignition source, then earthing terminals must be provided.
11

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.4 Recycling information
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be reused, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
- Metal straps should be sent for material recycling.
• Maintenance
- During maintenance oil and wear parts in the machine are replaced
-Allmetalpartsshoul
d be sent for material recycling
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling
- Oil and all non metal wear parts must be taken care of in agreement with local regulations
• Scrapping
- At end of use, the equipment shall be recycled according to relevant, local regulations. Beside the equipment itself, any
hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in the
absence of local regulations, please contact the local Alfa Laval sales company
12

4Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
4.1 Operation
Step 1
Always read the technical data thoroughly.
See chapter
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect operation.
Step 2
Never touch the valve or the pipelines when processing hot liquids
or when sterilizing. Burning danger!
TD 461-952
Step 3
Never touch the moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
TD 461-953
13

4Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
Step 4
Lubrication of valves:
1. Ensure smooth movement between lip seal (25) and
plug stem (23, 27).
2. Lubricate with Klüber Paraliq GTE 703 if necessary
(see page 18).
Shut-off valve Change-over valve
TD 474-009
Vacuum
Air Escape
P
Air Inta
k
Step 5
Lubrication of actuator
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate with Molykote Longterm 2 plus if necessary.
TD 474-010
1/4” Poly Flo
14

4Operation
Pay attention to possible faults. Study the instructions carefully.
The items refer to the parts list and service kits section.
4.2 Troubleshooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts. - See page 18!
Problem Cause/result Repair
External product leakage Worn or product affected lip
seal and/or O-ring
- Replace the seals
- Replace with seals of a
different rubber grade
Internal product leakage - Worn or product affected
plug seal - Replace the seal - Replace with a seal of a
different rubber grade
- Product deposits on
the seat and/or plug - Frequent cleaning
- Product pressure exceeds
actuator specification - Replace with a high pressure actuator - Use auxiliary air on the spring side
(do not exceed 3 bar)
- Reduce product pressure
Water hammer The flow direction is the
same as the closing direction
- The flow direction should be
against the closing direction
- Throttle air release of solenoid in
top unit
The valve does not
open/close
Product pressure exceeds
actuator specification
- Replace with a high pressure actuator
- Use auxiliary air on the spring side
- Reduce product pressure
15

4Operation
The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda.
HNO3= Nitric acid.
4.3 Recommended cleaning
Step 1
Always handle lye and acid with great care.
Caustic danger!
Always use
rubber gloves!
Always use
protective goggles!
Step 2
Never touch the valve or the pipelines when sterilizing.
Burning danger!
TD 461-952
Step 3
Clean the plug and the seats correctly.
Pay special attention to the warnings!
Lift and lower valve plug momentarily!
Shut-off valve Change-over valve
Step 4
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 70oC
1kgNaOH +100 l water =Cleaning agent.
+=
Cleaning agent.
2.2 l
33% NaOH
100 l
water
2. 0.5% by weight HNO3at 70oC
+=
Cleaning agent.
0.7 l
53% HNO3
100 l
water
16

4Operation
The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda.
HNO3=Nitricacid.
Step 5
1. Avoid excessive concentration of the cleaning agent.
2. Adjust the cleaning flow to the process.
3. Always rinse well with clean water after the cleaning.
Always rinse!
Clean water Cleaning agents
Step 6
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Step 7
Dust cleaning!
To avoid damage, all seal openings must be held free for dust. All
surfaces must be cleaned for dust.
17

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and lip seals in stock.
Check the valve for smooth operation after service.
5.1 General maintenance
Step 1
Always read the technical data thoroughly.
See chapter
Always release compressed air after use.
NOTE
All scrap must be stored/discharged in accordance
with current rules/directives.
Step 2
Never service the valve when it is hot.
Never service the valve with valve and pipelines under pressure.
Atmospheric
pressure
required!
Burning danger!
TD 461-954
Step 3
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air
Cutting danger!
Air
TD 461-953
Step 4
Never touch the moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
TD 461-953
18

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and lip seals in stock.
Check the valve for smooth operation after service.
Below are some guidelines for maintenance and lubrication intervals. Please note that the guidelines are for normal
working conditions in one shift.
Product wetted seals Actuator bushings complete
Preventive
maintenance
Replace after
12 months depending
on working conditions
Replace with Service Kit or
complete ATEX actuator after
5 years depending on
working conditions
Maintenance after
leakage (leakage
normally starts slowly)
Replace at the
end of the day
Replace when
possible
Planned
maintenance
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the valve
- Use the statistics for
planning of inspections
Replace after leakage
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the actuator
- Use the statistics for
planning of inspections
Replace after leakage
Lubrication
Before fitting
Klüber Paraliq GTE 703
or similar USDA H1
approved oil/grease
Before fitting
Molykote Longterm 2 plus
Pre-use check: Air
Open/close!
Air
1. Supply compressed air to the actuator.
2. Open and close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
TD 461-951
Recommended spare parts
Servicekits(seepage)
19

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
5.2 Dismantling of valve
Step 1
1a
Shut-off valve:
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove clamp.
3. Release compressed air (only NC).
4. Lift away the actuator.
5. Unscrew and remove valve plug.
6. Remove ground wire terminal from valve plug.
7. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings! Note!
Be careful not to damage the
bushing.
Note! For plug seal replacement please read instruction in
service kit.
TD 461-048_01
1b
Change-over valve:
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove lower clamp.
3. Release compressed air (only NC).
4. Lift away the actuator and upper valve body.
5. Supply compressed air to the actuator (only NO).
6. Unscrew and remove valve plug.
7. Remove ground wire terminal from valve plug.
8. Release compressed air (only NO).
9. Remove seat and O-rings.
10. Loosen and remove upper clamp.
11. Remove upper valve body.
12. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet.
See drawing, step 1a).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings!
Note! For plug seal replacement please read instruction in
service kit.
TD 461-044_3
UP
1c
Shut-offvalve-ReverseActing:
1. Loosen and remove lower clamp.
2. Remove lower bonnet and O-ring from lower body.
3. Loosen and remove middle clamp.
4. Lift away the actuator and upper valve body.
5. Supply compressed air to the actuator (only NC).
6. Unscrew and remove valve plug.
7. Release compressed air (only NC).
8. Remove seat and O-rings.
9. Loosen and remove upper clamp.
10. Remove upper valve body.
11. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet.
See drawing, step 1a).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings!
UP
TD 462-004_2
UP
20